IRVING — The FDA's approval in November allowing silicone gel breast implants for general cosmetic enhancement has resulted in a surge of appointments at plastic surgery offices across the country.

The nation's only maker of silicone breast implants is located at a nondescript factory in Irving.

Mentor Corporation vice-president Andrew Tymkiw explains the job of building breast implants as "big business." Tymkiw took News 8 on a rare tour of the 140,000 square foot plant.

While other manufacturers around the world hand-dip breast molds in liquid silicone, Mentor developed a top-secret robot that sprays on the perfect breast with precise accuracy.

"There's a lot of training involved in how to manipulate the shell and remove it," says Tymkiw.

Every implant goes through a rigorous 7-step process that includes curing — rotisserie chicken-style — and inspecting, like a blow-up balloon.

Tymkiw explains, "They're measured for thickness, any variation in shell, any surface imperfections or any cosmetic concerns."

All that is done before it's finally filled with silicone, which looks like a liquid, but isn't. The newest form of silicone is a much firmer texture. When cut open, it has the consistency of a gummy bear. It's designed not to leak.

The smallest implant made at the factory is about the size of a tennis ball.

The largest is about the size of a canteloupe. There are about a thousand variations in size and shape. Silicone makes them feel more like the real thing. That's something that makes women happier.

"And men!" Tymkiw added with a laugh.

It takes about two weeks to make a finished implant.

Every year, half a million individual "breasts" roll off the line ready for the operating room... or the runway.

E-mail jstjames@wfaa.com